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Keston Heat 45kw Installation Manual

1. SEQUENCER CONTROL OF MULTIPLE BOILERS In installations where the heat load is greater than the boiler capacity a solution is to use multiple boiler arrangements The ideal way to control a multiple boiler installation is with our modulating sequencer See below a typical installation with our optional modulating sequencer kit This device is capable of controlling up to 5 boilers Additional kits are required for greater than this Legend Non return valve Modulating Sequencer kit complete Safety valve with outdoor sensor and flow sensor Service valve Drain cock Mixing header Room Sensor System pump Keston Heat Installation 8 Servicing 19 INSTALLATION INSTALLATION 20 INSTALLATION 24 CONDENSATE DRAIN This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance All condensate pipework should conform to the following a Where a new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determini
2. lOROFSOFOROSOROFO 206210 10236 Keston Heat Installation 8 Servicing 37 INSTALLATION INSTALLATION INSTALLATION 48 KESTON HEAT WITH OPENTHERM 2 CHANNEL PROGRAMMABLE ROOM STAT Note 1 The OpenTherm 2 Channel Programamble Room thermostat is available from Keston as a kit Note 2 The Tank Temperature Sensor is available from Keston as a kit Diverter Valve Power Open 11091 405 i 4 ate Opentherm Fused le DO s D mm 2 Channel Spur I es D OI 7 Room ole POR Stat x es 153 Og D O 1 Tank Sensor I mr 206210 10238 49 COMMISSIONING AND TESTING A ELECTRICAL INSTALLATION B GAS INSTALLATION 1 Checks to ensure electrical safety should be carried out 1 The whole of the gas installation including the meter by a competent person should be inspected and tested for soundness and then T purged in accordance with the recommendations of the 2 ALWAYS carry out the preliminary electrical system relevant standards listed on page 4 by the installer checks i e earth continuity polarity resis
3. a we 2 2 S v s s Distance from flue centre line to outside wall surface lt gt For lengths greater than 8m increase offset X by 60mm 912mm 332mm for every additional 1m 8 PREPARING THE WALL IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Drill 4 boiler top fixing holes with a 12mm masonry drill and insert the plastic plugs m provided for the wall mounting plate e spp ND D 2 Drill the 2 boiler lower fixing holes with a 12mm 4 masonry drill insert the plastic plugs provided 3 Fix the wall bracket supplied in accessory box into place with 4 M10x70 hex head coach Su screws provided Z 9 Keston Heat Installation 8 Servicing INSTALLATION INSTALLATION INSTALLATION 9 MOUNTING THE BOILER Due care should be taken when lifting the boilers with respect to their weights see Table 2 on Page 2 Also refer to Safe Handling on Page 4 1 Lift the boiler onto the wall mounting plate as shown Note It is not necessary to hold the boiler at an angle to engage the wall mounting plate 2 Using the remaining coach screws secure the bottom of the boiler to the wall through the attached brackets 10 VENTILATION Keston ventilation requirements when installed in
4. sule O guJejxe Ol 1 pesn I C20 jou ysnw 4 g uonoeuuo2 5 716 OO jndino JN 1 Q O O oa i ON 1 Jo M OO 5 5 2 OO jeuondo OO NOY TIVLSNI Keston Heat Installation amp Servicing 24 INSTALLATION TIVLSNI 33 INTERNAL WIRING gt 1018 uueu onsouBeiq nss iq JOVEN dung MHG unes JOojsiuuJ9u L iis 10 6 Sec NOII A LI LIII aym OnOnOnOnen QN3931 25 Keston Heat Installation 8 Servicing INSTALLATION 26 INSTALLATION 34 BASIC CONTROLS DISPLAY C BURNER ON RESET 1st STAT 2nd STAT SELECT ENTER CHANGE EL Go KESTON HEAT USER INTERFACE Mains On When the mains to the boiler is switched on a screen similar to the following will be displayed The designation at the end of the bottom line indicates whether the boiler is suitable for Natural Gas initialising Please Wait U I 330 E18 Pri 00 54 Nat Gas Standby Mode Standby Mode Fo
5. CODE CTI 2 44 KESTON HEAT WITH PLAN SYSTEM 4 k Note that Frost Stat can be connected into CH call A Plan Valve L N E Fused Spur 1 1 E BI amp g L N Timer 3 HW On oe 206210 10232 HW a um 1 35 INSTALLATION INSTALLATION 36 INSTALLATION 45 KESTON HEAT WITH BOILER CONTROL OF PUMP AND DIVERTER VALVE Note 1 The Outside Senor provided can be used with this configuration Note 2 The boiler can use a Tank Sensor rather than a Cylinder Thermostat which is available from Keston as a kit 1 Note 3 Frost Thermostat can be connected into CH Call W Plan Valve L N E Diverter Valve Power Open r n Spur Boiler i OORT ez L 6 1 DO z lp Col EH 1 o C ara en AOE El Nie IS 9 5 gt ENS Ol OD ic o Og CIS 206210 10234 46 KESTON HEAT WITH SINGLE LOW LOSS HEADER V Keston Heat Installation amp Servicing INSTALLATION 47 KESTON HEAT WITH EXTERNAL CONTROLS VIA SWITCHED LIVE 0 10V INPUT OR OPENTHERM EXTERNAL CONTROLS VIA SWITCHED LIVE No
6. Boilers without 75mm sealed Water weather proof insulation Min 30mm Internal pipe Soil amp vent stack condensate trap must be fitted with a 75mm trap and visible air break Minimum connection height up to 3 storeys Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Boiler with 75mm sealed condensate trap nu Min 2 fe eee 0 Visible air break at plug hole Internal pipe Sink basin bath or shower with integral overflow and 75mm trap U Minimum 30mm internal pipe Water weather proof insulation 459 termination 2 25 Below grate 21 INSTALLATION INSTALLATION INSTALLATION 26 BOILER WATER CONNECTIONS The boiler flow and return pipes are terminated with 1 BSP male connections located at the bottom of the appliance Note This appliance is NOT suitable for use with a direct hot water cylinder Plastic plugs fitted into the open ends of the flow and return pipes must be removed before connecting the system pipework Upon installation a tee connection isolation valve and safety relief valve drain point must be fitted to the boiler flow return connection respectively See image opposite This hardware is provided within the boiler carton This allows isolatio
7. pipe work must be adequately supported Marley muPVC PVC C Solvent Weld Waste System 50mm and Polypipe System 2000 muPVC PVC C solvent weld waste 50mm are the only systems approved for this application Consideration must be given to Gas Safe Register bulletin 008 regarding flues in voids and inspection hatches The boiler casing must always be correctly fitted to the boiler when leaving the appliance operational External wall faces and any internal faces of cavity walls must be good Rubber collars are available for flue and air terminals to finish the external wall face around the terminals Part No C 08 00 07 0 AIR SUPPLY The Keston Heat is a room sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air E T Keston Heat Installation 8 Servicing 15 FLUE OUTLET INSTALLATION 14 ASSEMBLY PRACTICE Remove all plastic debris and burrs when installing air intake piping Plastic filings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower Prevent dust entering the air intake when cutting on building sites Blower failure which is determined to be caused by plastic filings or other debris will not be covered by guarantee INSTALLING FLUE AND AIR PIPES Important When installing the boiler on an existing system a new flue and air intake system MUST also be installed You MUS
8. 5 5 9 2 a 2 5 5 L 9 2 a 5 4 9 a L F 5 9 2 a L 5 5 u 56 Keston Heat Installation 8 Servicing FAULT FINDING 89 NO DISPLAY Is there 230Vac to the boiler at E Supply power to the boiler Is the wiring from the boiler terminal block to the main Connect the wiring from the terminal block PCB connected securely to the main PCB securely Is the cable from the main PCB to the user interface PCB Connect the cable from the main PCB to connected securely the user interface PCB securely Does the cable from the main PCB to the user interface Replace cable from main PCB to user PCB have continuity and is un damaged interface PCB Is the Fuse on the main PCB OK Check for shorts on Pumps Diverter Valve Fan Spark Generator Gas Valve and replace Fuse no Replace the user interface PCB still no display Replace main PCB ectifier LiveQut 9 2 a L 4 9 2 a 2 L 5 5 9 2 a 2 5 9 2 a 2 5 5 u 9 2 a 2 5 5 9 2 a i 4 Keston Heat Installation 8 Servicing 27 FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 90 0 10V INTERFACE 58 Is the boiler set to accept a 0 10V Input Is the boiler set to Winter Mode Is a voltage of between 2V and 10V being supplied to F with positive and negative connected corr
9. Heat 45 55 Installation and Servicing Instructions FAN POWERED HIGH EFFICIENCY MODULATING CONDENSING GAS BOILER CE PI No 86 CN 69 Heat 45 GC No 41 930 40 Heat 55 GC No 41 930 41 These instructions must left either with the user or next to the site gas meter Keston Heating PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 44 0 1482 443005 Fax 44 0 1482 467133 email info keston co uk www keston co uk COMPLIANT WITH BUILDING REGULATION PART L1 amp 12 SEDBUK A RATED benchmark GENERAL Table 1 Performance Data Natural Gas Keston Heat Model MN Boir ouni kw ______426 _____ _ OBA O Most Btu hr 145400 177800 7 kw Jj 1 2221 Mean 70 But ou 522 187700 Mean 7172 Btu hr 45300 45300 kw 432 RT Nett Boiler Input Btu hr 147400 179800 Max Rate Gross Btu hr 163400 199600 Boiler Input Btu hr 41600 41600 Min Rate m Btu hr 46100 46100 M Tena 161 2 196 9 i i i 2343 2861 1 93 95 O CO 40 596 2 HK mg kWh Weighted i ppm DAF cm Seasonal l 967 I SEDBUK 2009 Table 2 General Data KestonHeatModel IGasSuply 2H G20 20mbar 3P G31 37mbar Gas Supply Connection Gh Fiow Connection GU Retum Connection G
10. 50 Keston Heat Installation 8 Servicing FAULT FINDING 76 FALSE FLAME LOCKOUT ERROR 20 Check routing and integrity of internal boiler Reset the boiler does boiler work OK wiring is OK Check condition of Flame Sense Electrode and replace if deteriorated Disconnect the electrical connection to the Flame Replace Flame Detection Electrode Sense Electrode Is there continuity between the Electrode and earth Check routing and integrity of internal boiler wiring 77 LOW WATER PRESSURE Are the boiler and CH system filled with water and all datos and opena Isolation and Radiator Valves open Ensure wiring has continuity and is securely connected Check Safety Interlock Operation if fitted OK Replace Water Pressure Switch Does the wiring from the Water Pressure Switch to the PCB have continuity and is it securely connected 78 FLAME LOSS yes Check the Detection Electrode and associated Harness If the boiler is Reset does the boiler Ignite gt for continuity visual condition and position refer to for a short time and then Extinguish Frame 65 Check if the Condensate Pipe is blocked Check if the Flue is blocked Replace as necessary i 2 Is the Gas Pressure available boiler gt 18 Check Gas Supply and rectify fault Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB Is the following voltage available a
11. Is the thermistor value correct Does the Outside Sensor wiring between the boiler Ensure the wiring has continuity and is terminal strip and the PCB have continuity and is securely connected securely connected Replace main PCB 83 FLOW RETURN REVERSED 15 the System Pump connected the correct way Check that the system pipework is correct 2 4 2 a 4 2 2 4 2 Hi 4 2 2 Hi 4 2 2 4 Keston Heat Installation 8 Servicing 52 FAULT FINDING 84 CYLINDER THERMISTOR FAULT Change menu setting for DHW Sensor to Switched Live See Frame 41 Is the wiring securely connected at both the boiler and cvlinder thermistor Securely connect the wiring at both y _ the boiler and cylinder thermistor Disconnect the wires to the cylinder thermistor Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 At 60 C expect 2 400 2 600 Q fala iiu Lis i bs AE Ensure the wiring has continuity and is s the thermistor value correct securely connected Does the cylinder thermistor wiring between the boiler terminal strip and the PCB have continuity and is securely connected Is a DHW Thermistor connected to the boiler Replace main PCB 85 EXTERNAL INTERLOCK OFF Ensure that a link wire is secu
12. Burner On Burner On DHW Thermostat DHW Thermostat Flow Temp Flow Temp operates Domestic Hot Water Mode DHW Thermistor DHW 230V Operation DHW 230V Operation If there is an ongoing Domestic Hot Water Demand using SwithedLive2On Burner Power 100 a DHW Thermistor screens similar to the following will be Burner On lt Burner On displayed DHW Setpoint 65 DHW Setpoint 65 C Line 2 indicates whether Switched Live or OpenTherm is Hot Water Temp 65 C Hot Water Temp 65 C controlling the boiler Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Burner Power and Hot Water Temp will vary as the boiler operates See Frame 36 for adjusting DHW Setpoint See Frame 41 for configuring the boiler to use a DHW Thermistor continued Keston Heat Installation amp Servicing INSTALLATION 35 BASIC CONTROLS DISPLAY CONTINUED Central Heating Mode If there is an ongoing Central Heating Demand screens similar to the following will be displayed Line 2 indicates whether Switched Live 1 2 or OpenTherm is controlling the boiler Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Outside temperature will only be shown if an outside sensor is connected to the boiler Burner Power and Flow Temp will vary as the boiler operates See Frame 36 for adjusting Flow Setpoint CH 230V Operation Switched Live 1
13. c gt gt gt connection height up to 3 storeys Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to the discharge point with no horizontal sections in which condensate might collect connections to an external soil vent stack see Fig 4 Insulation measures as described should be used When a rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid revers
14. 45 55 176273 176360 176313 177038 62 GAS VALVE REPLACEMENT Refer to Frame 53 2 Remove the upper front panel Refer to frame 55 3 Remove the fan and gas assembly Refer to frame 56 4 Remove the 3 screws holding the gas valve to the venturi 5 Remvove the four screws retaining the gas valve 6 Remove the venturi from the mixture chamber before removing the gas valve 7 Fit new gas valve to venturi using the new seal provided ensure gas injector is fitted correctly 8 Re assemble in reverse order checking seals and gaskets and replacing if faulty or damaged 9 Check the operation of the boiler Refer to frame 53 Gas Management Assembly Part No s Model Fan Venturi Valve Injector 45 55 176273 176360 176313 177038 44 Keston Heat Installation amp Servicing SERVICING 63 VENTURI REPLACEMENT Refer to Frame 53 Remove the front panel Refer to frame 55 Remove the fan and gas assembly Refer to frame 56 Poe NS Remove venturi from fan mixture chamber and gas valve Refer to frame 61 amp 62 64 IGNITION ELECTRODE REPLACEMENT 1 Refer to Frame 53 Remove the front panel Refer to frame 55 Pull off the spark lead and earth connection Remove the two retaining cap head screws Pull out the electrode and pull off the old gasket ec Replace with new electrode and gasket supplied checking the spark gap is 4mm
15. Reassemble in reverse order 8 Check the operation of the boiler Refer to frame 53 65 DETECTION ELECTRODE REPLACEMENT Refer to Frame 53 Remove the front panel Refer to frame 55 Pull off the HT lead and earth connection Remove the two retaining cap head screws Pull out the electrode and pull off the old gasket Replace with new electrode and gasket Reassemble in reverse order NN Boo N S Check the operation of the boiler Refer to frame 53 Keston Heat Installation amp Servicing Replace with new venturi ensuring the gas orifice is fitted and seal is replaced Re assemble in reverse order checking seals and gaskets and replacing if faulty or damaged Check the operation of the boiler Refer to frame 53 45 SERVICING SERVICING SERVICING 66 AUTOMATIC AIR VENT REMOVAL 1 Refer to Frame 53 2 Remove the front panel Refer to Frame 55 3 Unscrew the air vent A from the self sealing fitting B on the top left of the flow pipe 4 Fit the new air vent 5 Ensure the black plastic vent cap is loose to allow air to escape Air in the boiler could cause damage to the heat exchanger 6 Re assemble in reverse order 7 Check the operation of the boiler Refer to Frame 53 67 WATER PRESSURE SWITCH REPLACEMENT Refer to Frame 53 Remove the front panel Refer to frame 55 Isolate the water circuit and drain the boiler Disconnect the electrical connectio
16. Check Fan Wiring Check Fan Elow Flue Thermistor Fault Check Flow Thermistor Wiring Check Flow Thermistor 10K 25 C 2K at 66 No CH but DHW OK No DHW but CH OK Blank Display CH Continues to run when Timer is off Flow Temperature Setpoint cannot be increased to 82 FAULT FINDING Go to Frame 74 Overheat Lockout Go to Frame 75 Ignition Lockout 5 resets within 15 mins Turn power off and on Go to Frame 76 False Flame Lockout Go to Frame 77 Low Water Pressure Go to Frame 78 Flame Loss Go to Frame 79 Fan Fault Go to Frame 80 Flow Flue Thermistor Fault Go to Frame 87 No CH but DHW OK Go to Frame 88 No DHW but CH OK Go to Frame 89 Blank Display Ensure Night Setback not enabled See Frame 39 Ensure Flow Temp is not limited within Installer Mode See Frame 40 Keston Heat Installation 8 Servicing Return Thmr Fault Check Return Thermistor Wiring Check Return Thmr 10K 25 C 2K at 66 Outside Sensor Fault Check Outside Sensor Wiring Check Outside Sensor 10K 25 C 2K at 66 Flue Thermistor Fault Check Flue Thermistor Wiring Check Flue Thermistor 10k 25 2k 66 Low Mains Voltage Less than 160V Check Local Generator Contact Electricity Provider PCB Fault Ensure BCC fitted Replace PCB Elow Return Reversed Check Pump Check System Pipework Cylinder Thermistor Fault Check Cylinder Thermistor Wiring Check Cylinder
17. Off Press and to change to required setting then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation CHANGING 2ND SWITCHED LIVE INPUT BETWEEN DHW amp CH To change the 2nd switched live input from DHW operation factory default to CH operation press SELECT and then hold and down together for more than 5s and the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Set Booster 2nd SL DHW CH CH DHW Priority Set Max Flow Temp Press SELECT and the following screen will be displayed 2nd SL DHW CH DHW CH2 Priority SL2 CH2 Priority 511 Press and to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation continued INSTALLATION INSTALLATION INSTALLATION 40 KESTON HEAT USER INTERFACE ADVANCED OPERATING INSTRUCTIONS CHANGING DHW PRIORITY The boiler default setting is DHW always has priority ahead of CH It is possible to change this so CH always has priority ahead of DHW or the boiler alternates between DHW and CH every 10 mins Press SELECT and then hold and down together for more than 5s the follo
18. above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard The minimum spacing between the balcony and the terminal should be 75mm in order to allow a terminal guard to be fitted Terminal guards are available from boiler suppliers Ensure that the guard is fitted centrally The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 2008 In IE refer to 1 5 813 2002 The flue must be installed in accordance with Building Regulations and the recommendations of BS 5440 1 2008 for inputs up to 70kW nett Keston Heat Installation 8 Servicing WATER CIRCULATION SYSTEM The boiler must NOT be used for direct hot water supply The hot water storage cylinder MUST be of the indirect type Single feed indirect cylinders are not recommended and MUST NOT be used on sealed systems The appliances are NOT suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water The hot water cylinder and ancillary pipework not forming part of the useful heating surface should be lagged to prevent heat loss and any possible freezing particularly where pipes run through roof spaces and ventilated underfloor spaces The boiler must be vented Draining taps MUST be located in acc
19. can be connected to the DHW Thermistor input Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the KNOB clockwise until the following screen is displayed Installer Mode O S Room Temp DHW Sensor Factory Settings Anti Legion Temp Press SELECT and the following screen will be displayed DHW Sensor Heating Only DHW Thermistor DHW Switched Live Press and to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation continued 33 INSTALLATION INSTALLATION 34 INSTALLATION 42 KESTON HEAT USER INTERFACE ADVANCED OPERATING INSTRUCTIONS CONT D REVERTING TO FACTORY SETTINGS Press SELECT hold and together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode DHW Sensor Factory Settings Anti Legion Temp Anti Legion Enable Press SELECT and the following screen will be displayed Factory Settings Reset Press ENTER and a screen similar to the following will be displayed Factory Settings Are you sure Press Enter to Reset Press Select not to Reset Press EN
20. system pump connects to a control system pump set for shunt pump Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Set Night Setback DHW Pump Valve Set Booster 2nd SL DHW CH Press SELECT and the following screen will be displayed DHW Pump Valve Pump Valve Power Open Press for more Press and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Keston Heat Installation 8 Servicing d Note Booster Function is only operational if Outside Sensor has been connected If Booster function is enabled and CH Demand is ongoing for more than 10 minutes then the Flow Temp target is increased by 10 When the Burner switches off the temperature is reset Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode DHW Pump Valve Set Booster 2nd SL DHW CH CH DHW Priority Press SELECT and the following screen will be displayed Set Booster On
21. Both the 50mm flue outlet terminal and the 50mm air inlet terminal are supplied with the flue pack and are illustrated in Fig 1 and must be used in ALL installations Both terminals are identical Keston Heat Installation 8 Servicing 13 FLUE OUTLET INSTALLATION 12 FLUE SYSTEM CONT D TERMINATION OF THE FLUE AND AIR The flue and air pipes may terminate independently through any external walls within the same dwelling except on TERMINAL POSITIONS opposing walls within the maximum lengths shown in Fig 3 amp 4 Minimum Separation The air pipe must have an elbow and 150mm length of pipe i 140mm directed downwards with a termination grill fitted The air pipe can be situated at the side or beneath the flue pipe to a minimum dimension of 140mm see diagram below It must not be sited above the flue pipe The flue and air pipes must extend by at least 40mm from the wall surface Condensing boiler emit a visible plume of water vapour from Acceptable the flue terminal this is normal It is the responsibility of the ee installer to judiciously select a terminal location that does not ER d Air Pipe cause a nuisance If either the flue or air terminal is below a height of 2m from Te ground level a terminal guard must be fitted MAXIMUM LENGTHS Due to the resistance presented by extended flue length a slight reduction in maximum boiler output will occur where combined flue and air lengths in excess
22. On Burner On Flow Setpoint Flow Temp Boiler Frost Protection Mode If the boiler flow temperature drops below 5 screens similar to the following will be displayed Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Outside temperature will only be shown if an outside sensor is connected to the boiler Burner Power and Flow Temp will vary as the boiler operates Boiler Frost Protect Burner Power Burner On Frost Setpoint Flow Temp System Frost Protection Mode If an Outside Sensor is fitted and the Outside Temperature drops below the system frost protection temperture setpoint a screen similar to the following will be displayed Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Flow Temperature and Outside Temperature will vary as the boiler operates See Frame 40 for adjusting the system frost protection temperature setpoint Cylinder Frost Protection Mode If a Domestic Hot Water Thermistor is connected to the boiler and the DHW temperature drops below 5C a screen similar to the following will be displayed Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Burner Power Hot Water Temp and Outside Temp will vary as the boiler operates Outside temperature will only be shown if an outside sensor is connected to the boiler Cylinder Frost Protect Burner Power Burner On Frost Setpoi
23. REMOVAL OF SUMP COVER Refer to Frame 53 Remove the front panel Refer to frame 55 Prepare boiler for possible water spillage during the process Remove the two screws from the helmholtz clean out cover and pull away from the boiler Scrape out any deposits 6 Re assemble in reverse order checking seals and gaskets and replacing if faulty or damaged PON a 60 CONDENSATE TRAP 1 Refer to Frame 53 2 Unscrew the nut and disconnect the flexible pipe 3 Unscrew the top nut and remove the condensate trap 4 Remove the ball from the condensate trap and flush out with water to remove any debris 5 Reassemble in reverse order 6 Check the operation of the boiler Refer to frame 53 Keston Heat Installation amp Servicing 43 SERVICING SERVICING SERVICING 61 FAN REPLACEMENT 1 Refer to Frame 53 2 Remove the upper front panel Refer to frame 55 3 Remove the fan and gas assembly Refer to frame 56 4 Remove the screws retaining the venturi to the fan 5 Remove the extended nuts holding the venturi to the fan 6 Remove the screws retaining the fan plate 7 Transfer venturi and gas valve assembly to the new fan 8 Re assemble in reverse order checking seals and gaskets and replacing if faulty or damaged 9 Check the operation of the boiler Refer to frame 53 Gas Management Assembly Part No s Model Fan Venturi Valve Injector
24. Registered Engineer or in IE by a competent person An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required A minimum working gas pressure of 17 5mbar MUST be available at the boiler inlet for Natural gas Do not use pipes of smaller size than the boiler inlet gas connection The complete installation MUST be tested for gas soundness and purged in accordance with the appropriate standards listed on page 4 FLUE INSTALLATION Individual air supply and flue outlet pipes are used The material used for the flue outlet and the air intake systems must be muPVC to BS 5255 In addition the flue outlet and air intake pipework must be marked BSEN 1566 1 and the fittings must be marked BSEN 1329 Marley muPVC Solvent Weld Waste System 50mm and Polypipe System 2000 muPVC Solvent Weld Waste System 50mm are recommended DO NOT USE ABS PIPE OR FITTINGS IMPORTANT It is the responsibility of the installer to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors other sources of natural air infiltration or forced ventilation air conditioning If this should occur the appliance MUST be turned OFF labelled as unsafe and corrective action taken Where the lowest part of the terminal is fitted less than 2m 80 above a balcony
25. Stat clockwise until a screen similar to following is displayed Keston 45kW Set Stat 2 Temp Set Off Sum Win Out Sensor Slope Normal Operation Press SELECT and a screen similar to the following will be displayed Set Off Sum Win Standby Summer Winter Press for more Press and to change to required setting press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation SETTING THE OUTSIDE SENSOR SLOPE Note that an Outside Sensor must be fitted to the boiler for this feature to be active this will be detected automatically Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending on the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 151 stat clockwise until a screen similar to following is displayed Keston 45kW Set Off Sum Win Out Sensor Slope State of Inputs State of Outputs Press SELECT and a screen similar to the following will be displayed Out Sensor Slope 1 5 Note that a higher number gives a higher room temperature and a lower number gives a lower room temperature Press and to change to required setting press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation contin
26. Thmr 10K 25 C 2K at 66 C Ext Interlock Off External Interlock Operated Reset Interlock BCC Fault Ensure BCC fitted correctly Replace BCC Pump runs during the night Boiler does not respond to 0 10 Input DHW Thermistor used and DHW does not end Error 20 Pump only runs at maximum speed Go to Frame 81 Return Thermistor Fault Go to Frame 82 Outside Sensor Fault Go to Frame 80 Flow Thermistor Fault Contact Electricity Provider Replace Main PCB Go to Frame 83 Flow Return Reversed Go to Frame 84 CylinderThermistor Fault Go to Frame 85 Ext Interlock Off Go to Frame 86 BCC Fault Ensure system Frost Protection Temp Setpoint is not set too high Go to Frame 40 Go to Frame 38 0 10V Interface Ensure boiler set for DHW Thermistor See Frame 41 Go to Frame 76 False Flame Lockout Check LV wiring from PCB to pump 49 2 4 2 a 4 2 2 4 2 a 4 2 2 Hi 4 2 2 4 FAULT FINDING 74 OVERHEAT LOCKOUT Has PCB just been replaced Reset Boiler no Are the boiler and CH DHW system ne Fill and vent the system and open all filled with water and are all isolation isolation valves then reset the boiler valves and radiator valves open yes Check the flow and return Is the flow return differential across thermistors refer to F
27. comply with BS 1394 Safety Additional Valve AAV System Primary Flow Header Primary Return Installation of air bleed valves at the high spot s in the system will allow for air elimination when filling the system and will allow re venting in a day or so after all air has been driven out of solution Note With the boiler firing at minimum rate the temperature differential should not be greater than 35 C Lower flow rates generating higher temperature differentials will lead to lock out of the boiler In installations where all radiators have been provided with thermostatic radiator valves it is essential that water circulation through the boiler is guaranteed This can be best achieved by means of a differential pressure valve which is installed in a bypass between the flow and return pipes The bypass should be fitted at least 6m from the boiler and should use a minimum size of 28mm pipe The bypass should be capable of allowing a minimum flow rate to achieve a temperature differential of no greater than 35 C at minimum rate WATER TREATMENT These boilers incorporate an ALUMINIUM heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Keston INVALID Keston recommend Water Treatment in accordance with Guidance Notes on Water Treatment in Central Heating Systems Keston recommend the use of Fernox Copal or MB1 or GE Betz Sentinel X100 inhibitors and associat
28. flues and ventilation for gas appliances of rated input not exceeding 70kW net 1st 2nd and 3rd family gases Specification for installation of flues Specification for installation and maintenance of ventilation for gas appliances Installation and maintenance of gas fired hot water boilers of rated input not exceeding 70kW net BS 5440 Part 1 Part 2 BS 6798 BS 6880 Low temperature hot water heating systems of output greater than 45kW Fundamental and design considerations Selection of equipment Installation commissioning and maintenance Part 1 Part 2 Part 3 BSEN 12828 2003 Heating Systems in buildings Design for water based systems BSEN 12831 2003 Heating Systems in buildings Method for calculation of the design heat load Specification for Expansion vessels using an internal diaphragm for sealed hot water heating Systems BSEN 14336 2004 Heating Systems in buildings Installation and commissioning of water based heating systems Where reference is made throughout these instructions 1 5 813 2002 Domestic Gas Installations reference should also be made to 1 5 820 2000 Non Domestic Gas Installations as applicable BSEN 13831 SAFE HANDLING This boiler may require 2 or more operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler may include the use of a sack truck and involve lifting pushing and
29. 0 10V Operation Burner Power Burner On Burner Setpoint Target Flow Temp 0 10V Operation Burner Power Burner On Flow Setpoint Flow Temp continued 27 INSTALLATION INSTALLATION INSTALLATION 36 KESTON HEAT USER INTERFACE BASIC OPERATING INSTRUCTIONS SETTING STAT 1 TEMPERATURE Rotate 1st Stat and the following screen will be displayed Stat 1 Temp Rotate the knob until the desired temperature is shown and then press ENTER to store When operating under stat 1 control the boiler flow temperature target will be that set here SETTING STAT 2 TEMPERATURE Rotate 2nd Stat and the following screen will be displayed Stat 2 Temp Rotate the knob until the desired temperature is shown and then press ENTER to store When set for DHW operation see Frame 39 and operating under DHW control the boiler flow temperature will be that set here 4 C When set for CH operation see Frame 39 and operating under CH control the boiler flow temperature will be that set here 28 SETTING SUMMER WINTER AND STANDBY OPERATION Note that Standby Mode will disable Domestic Hot Water and Central Heating Summer Mode will disable Central Heating Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 151
30. 8 0 00 07 0 Support any pipes whose route could be displaced either of its own accord or by accident Any horizontal run over 1m or vertical runs of any length must always be supported Brackets should be placed at intervals of approximately 1m Brackets should be loose enough on the pipe to allow thermal expansion and contraction movement Flue pipework through walls MUST be sleeved to allow thermal expansion and contraction movement Check all connections for security and re seal any joints using solvent cement where soundness may be in doubt e Check Sample plug for free movement and seating Note It is equally important to seal the air inlet with solvent cement as the flue outlet pipe joints Flue Sampling Point Keston Heat Installation amp Servicing INSTALLATION 15 FITTING THE FLUE SLEEVING Cut hole in wall preferably with 60mm core bore tool Measure wall Thickness Cut sleeve length to match wall thickness amp remove burrs Grout sleeve into wall with flange on external face Slide flue pipe into sleeve checking it is free to slide Slide Flexible wall seal over flue pipe and push centre ring up to sleeve flange when cold Locate wall plate over flexible wall seal and clamp in place using the raw plug pack Affix flue terminal During boiler test check that the flue end is free to expand and contract with flexible wall seal Flue Terminal Flue P
31. AGING REMOVAL The boiler should be laying on its back with the straps Remove the packing piece from the top of the boiler removed Check the contents against list in Frame 6 Unpacking Carefully read the installation instructions before proceeding Note some items are contained within the top packing piece The boiler may now be stood on its base with the cardboard bottom packing piece still in place to protect the Remove the accessory Box Remove the outer packing sleeve Remove the protective cardboard wall mounting template connections Due care should be taken when standing up from the front of the boiler the boilers with respect to their weights see Table 2 on page 2 6 UNPACKING The boiler is supplied fully assembled in one pack When unpacking the boiler check the contents against the list shown Do not dispose of the packaging until all contents are accounted for as some parts are held within the cardboard packing pieces Pack Contents lt A Fully assembled boiler B Installation amp Servicing User Instructions Log Book Wall mounting template Condensate Trap M10 x 70 Hex Head Coach Screws 6 off G M10 Wall Plug 6 off 31100 Accessory Box Gas cock Ball Valve 2 off M1 Tee Pressure Relief Valve M1 Tee Drain Nipple Drain Nipple Wall Mou
32. T NOT re use existing flue or air pipework components e Remove the flue adaptor and air spigot from the flue pack supplied with the boiler Remove boiler front panel Frame 55 Remove air intake blanking plate by unscrewing 4 x M5 screws and put to one side leaving sponge gasket in place Fix air spigot to boiler using the 4 M5 screws see diag below Ensure sponge gasket is in place and not damaged Insert the flue adaptor into the flue manifold on the top of the boiler and secure using the 6 M5 screws provided Measure cut and check the air and flue pipes to pass to the exit from the wall s or ceiling Always thoroughly deburr all pipes and most important remove shavings from within the pipe Assemble using solvent weld cement the pipework from the boiler connections to the exit from the first wall ceiling remount the boiler if removed Care must be taken when applying solvent weld to ensure it does not come into contact with the sample plug When pushing pipe through walls ensure grit and dust is not allowed to enter the pipe Ensure pipes are fully engaged into sockets and solvent welded with no leaks 16 Using the same methods drill any further holes always covering existing pipework cut and assemble the pipework From outside complete the two terminations See Frame 11 Flue System and make good all holes Wall sealing collars are available to make good hole areas on the wall face part number 0
33. TER and screen similar to the following will be displayed Factory Settings Reset Press Select then Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation CHANGING THE ANTI LEGIONELLA TEMPERATURE Note Anti Legionella Temp Function is only operational if a DHW Thermistor has been connected Care should be taken reducing this temp as unsafe condition could result Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Factory Settings Anti Legion Temp Anti Legion Enable BUS Address Press SELECT and the following screen will be displayed Anti Legion Temp 70 C Press and to change to required setting press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation DISABLING THE ANTI LEGIONELLA FUNCTION Note that the Anti Legionella Temperature Function is only operational if a Domestic Hot Water Thermistor has been connected Care should be taken in disabling this function as an unsafe condition could result Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set S
34. Table 1 You should be able to read at least 90 of the nominal Keston Heat 45 Keston Heat 55 Max Rate 0 5 9 3 9 5 Min Rate 0 5 8 4 8 4 OPERATING SEQUENCE yes Pump On emp lt setpoint yes Fan On 20s Fan Pre purge Gas Valve On Spark Generator On 3s Ignition Period Flame detected ne yes Spark Generator Off 1st Stabilisation Period Demand On amp Temp lt Set point amp Anti cycle done Burner Output controlled relative to Heat Demand by varying Fan Speed Burner On Demand n off or Temp gt setpoint Note The fan runs for Gas Valve Off 4 mins after the burner switches off Pump Overrun Fan off Pump off Keston Heat Installation amp Servicing Heat Demand Off 39 INSTALLATION INSTALLATION INSTALLATION 51 GENERAL CHECKS Make the following checks for correct operation 1 The correct operation of ANY secondary system controls should be proved Operate each control separately and check that the main burner or circulating pump as the case may be responds 2 Water circulation system a With the system HOT examine all water connections for soundness b With the system still HOT turn off the gas water and electricity supplies to the boiler and drain down to complete the f
35. U 4 0 58 407 Electricity Supply f 230V 50Hz lPRaing Nommalfuedia Conen 0 2 CondensateDran __ 7778 ____________________ The value is used in the UK Government s Standard Assessment HEALTH amp SAFETY DOCUMENT NO 635 Procedure SAP for energy ratings of dwellings The test data from which it has been calculated have been certified by a notified body The electricity at work regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory Note obligations Natural gas consumption is calculated using a calorific value of IMPORTANT These appliances are CE certified for safety 37 8MJ m 1038Btu f gross or 34 MJ m 910 Btu ft nett at and performance It is therefore important that no external 15 and 1013 25 mbar control devices e g flue dampers economisers etc are a For l s divide the gross heat input kW by the gross C V ofthe directly connected to these appliances unless covered by gas MJ m these Installation and Servicing Instructions or as otherwise b Forft h divide the gross heat input Btu h by the gross of recommended by Keston in writing If in doubt please enquire the gas c For mh multiply Vs by 3 6 Any direct connection of a control device not approved by Keston could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations 2 Keston H
36. VICING 57 BURNER REMOVAL 4 1 Refer to Frame 53 2 Remove the front panel Refer to frame 55 3 Remove the fan and gas valve assembly Refer to frame 56 4 Remove the six eight extended nuts securing the burner to release the burner body 5 Lift the burner body to remove it from the studs and lift the burner out of its recess 6 The burner can now be cleaned on the back face only the metal fibre surface must not be touched The burner must be replaced if it shows signs of damage 7 After cleaning the burner replace it in the recess and check the burner body seal for signs of damage If damage is apparent it must be replaced 8 Reassemble in reverse order The six or eight extended nuts should be fitted following a diagonal tightening sequence twice The nuts should be secured firmly 9 Check the operation of the boiler Refer to Frame 53 58 HEAT EXCHANGER INSPECTION CLEANING Refer to Frame 53 Remove the front panel Refer to frame 55 Remove the fan and gas assembly Refer to frame 56 Remove the burner Refer to frame 57 Remove the ignition and detection electrodes Refer to frame 64 and 65 6 Inspect the heat exchanger for signs of aluminium oxide deposits If necessary clean the heat exchanger by spraying water down the flue ways 7 Re assemble in reverse order checking seals and gaskets and replacing if faulty or damaged 8 Check the operation of the boiler Refer to frame 53 Od 59
37. W Set Stat 2 Temp Set Off Sum Win Out Sensor Slope State of Inputs Press SELECT and the following screen will be displayed Set Off Sum Win Standby Summer Winter Press for more Press and until the followint screen is displayed Set Off Sum Win Minimum Maximum Press for more Press ENTER and the boiler will go to Maximum Rate for 5 minutes Operation will be automatically reset at the end of 5 minutes 41 SERVICING SERVICING 42 SERVICING 56 REMOVAL OF FAN AND GAS VALVE ASSEMBLY Refer to Frame 53 Remove the upper front panel Refer to Frame 55 Remove the two screws retaining the flue tube to the heat exchanger Lift the lower section of flue upwards to disengage from the sump then twist outwards and pull down to completely remove Disconnect condensate pipe from upper flue elbow Remove the flue tube elbow fixing screws and remove elbow by pulling downwards 7 Disconnect the electrical connections from the gas valve s 8 Disconnect the electrical connections from the fan 9 Undo the gas valve union nut nuts and retain the fibre washer s 10 Remove the four nuts screws retaining the fan assembly and remove the fan assembly 11 Inspect amp clean as necessary 12 Re assemble in reverse order checking seals and gaskets and replacing if faulty or damaged Inlet Gas Pressure Test Point Keston Heat Installation amp Servicing SER
38. a compartment up to 70kW BS5440 To a room or internal space To outside Air 263 wa ___ ___ Keston Heat 45 55 multiple boiler applications Detail reference should be made to BS 6644 for inputs If ventilation is to be provided by means of permanent between 70kW 1 8MW net In IE refer to the current high and low vents communicating direct with outside air edition 1 5 820 The following notes are for general then reference can be made to the sizes below For other guidance only ventilation options refer to BS 6644 In IE refer to the current edition of 1 5 820 12 Keston Heat Installation 8 Servicing INSTALLATION 11 FLUE SYSTEM Note When installing a replacement boiler a new flue system must be used Do not re use the existing boiler flue installation Design Individual air supply and flue outlet pipes are used as standard The material used for flue outlet amp or air inlet must be muPVC PVC C to BS 5255 and or BSEN 1566 1 and BSEN 1329 of an internal diameter of 51mm i e nominal 50mm diameter muPVC solvent weld waste pipe Marley muPVC PVC C Solvent Weld Waste System 50mm and Polypipe System 2000 muPVC PVC C solvent weld waste 50mm are the only systems approved for this application The following pipes and fittings are approved Polypipe System 2000 muPVC solvent Weld Waste System 50mm Poy Pieco Marley muPVC solvent Weld Waste System 50
39. al operation CHANGING THE MINIMUM FLOW TEMPERATURE SETPOINT Boiler default setting is that minimum flow temperature setpoint is 30 C This feature limits the minimum flow temperature that can be set in the Basic Operating Mode Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st Stat clockwise until the following screen is displayed Installer Mode Set Max Flow Temp Set Min Flow Temp Sys Frost Protect Soft Start Time Press SELECT and the following screen will be displayed Set Max Flow Temp 30 Press to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation continued Keston Heat Installation amp Servicing INSTALLATION CHANGING THE SYSTEM FROST PROTECTION TEMP SETPOINT Note that System Frost Protection Function is only operational if an Outside Sensor has been connected The CH pump is switched on if the Outside Temp is less than the System Frost Protection Temp The CH pump is switched off if the Outside Temp is more than the System Frost Protection Temp 5 C The boiler default setting is the system frost protection temp setpoint is 10 C Press SELECT and then hold and down together for mor
40. arge of water or steam is visible but will not cause hazard to user or plant Pressure Gauge A pressure gauge covering at least the range 0 4bar must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel 1 General a Detail reference should be made to the appropriate standards listed on page 4 The information and guidance given below is not intended to override any requirements of these publications or the requirements of the local authority gas or water undertakings The installation should be capable of working with flow temperatures of up to 90 C and a temperature differential of up to 20 C Expansion Vessel All components of the system including the heat Expansion vessels used must comply with BS EN exchanger of the indirect cylinder must be suitable for a 13831 Connection to the system must not incorporate working pressure of 4 bar 60 Ibf in2 and temperature of an isolating valve 110 C Care should be taken in making all connections so that the risk of leakage is minimised The boiler is fitted with an automatic air vent located in the left top side of the interior This air vent must never be shut off as this could result in dry firing of the boiler and subsequent damage to the heat exchanger primary flow Safety Valve supplied with boiler and return Type BA backflow A spring loaded safety val
41. check for water soundness d Balance the system 3 Check the condensate drain for leaks and check it is discharging correctly 4 Finally set the controls to the User s requirements Note f an optional programmer kit is fitted then refer to the instructions supplied with the kit IMPORTANT Point out to the owner that the boiler must have regular maintenance and cleaning at least annually in order to ensure reliable and efficient operation Regular attention will also prolong the life of the boiler and should preferably be performed at the end of the heating season After servicing complete the service section of the log book and return to the owner or their representative Recommend that a contract for this work should be made with the regional gas authority or a Gas Safe Registered Engineer In IE servicing work must be carried out by a competent person Check the water system is correctly filled and free of air Air in the boiler could cause damage to the heat exchanger For this reason the automatic air vent in the left top side must never be shut off Check the jacket front panel is correctly fitted ensuring that a good seal is made Secure the controls fascia in place With the system hot examine all water connections for soundness Check the gas rate and measure the combustion content The CO CO ratio of the flue gas should not be greater than 0 004 ratio and the CO should match the val
42. displayed State of Outputs Boiler Pump On DHW Pump Valve Off Fan 3000rpm Press for more The state of the outputs will vary as the boiler operates Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Keston Heat Installation amp Servicing VIEWING THE FAULT HISTORY OF THE BOILER Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 1st stat clockwise until a screen similar to the following is displayed Keston 45kW State of Outputs Fault History Show Hours Run Normal Operation Press SELECT and a screen similar to the following will be displayed Fault History Max 10 Fault 1 Latest Ignition Lockout 16 23 days ago Press for more The Fault History will vary depending on the operation of the boiler Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation VIEWING THE BOILER HOURS RUN Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 1st
43. e air temperature and sends a signal to the boiler which adjusts the maximum boiler flow temperature in response If outside air temperature is greater than the system design temperature the boiler flow temperature is reduced providing running cost savings The boiler will operate in the condensing mode more frequently increasing The sensor operation may be configured by adjustment of the boiler operating Switch having a 3mm 1 8 contact separation in both poles or a plug and unswitched socket serving only the boiler and System controls The means of isolation must be accessible to the user after installation When making mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors such that if the cord anchorage should slip the current carrying conductors become taut before the earthing conductor 4 self adhesive cable clips are provided to aid routing of the wiring across the bottom panel of the boiler 30 FITTING THE WEATHER COMPENSATION KIT SUPPLIED IN ACCESSORY BOX Kit Contents A Outside Air Sensor 3610011 3 Input terminals are available for connecting a variety of system controls for heating demand and optionally for DHW demand Heating demand can be controlled by 230V programmer and or room thermostat programmable room thermostat Modulating sequencer kit a bms outside temperature
44. e flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chill at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates in a purpose designed soak away see BS 6798 any above ground condensate drain pipe sections should be run and insulated as described above See Fig 7 Unheated Internal Areas Internal condensate drain pipes run in unheated areas e g lofts basements and garages should be treated as external pipe Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual Figure 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate Min 19mm P di Internal pipe Sink basin bath or shower Internal soil amp vent stack Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued Keston Heat Installation 8 Servicing INSTALLATION 25 CONDENSATE DRAIN CONT D Figure 3 Connection of a Condensate Pump Typical Me
45. e than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Set Min Flow Temp Sys Frost Protect Soft Start Time O S Room Temp Press SELECT and the following screen will be displayed Sys Frost Protect 10 C Press and to change to required setting press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation CHANGING THE SOFT START TIME The Soft Start Time is the time for which the boiler will run at the ignition rate after a flame is detected This feature helps make the boiler fully compatible with the CH DHW system The default Soft Start time is 5s Care should be taken in adjusting this feature as system noise and or boiler lockout could occur Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Sys Frost Protect Soft Start Time O S Room Temp DHW Sensor Press SELECT and the following screen will be displayed Soft Start Time 5s Press and to change to required setting then press ENTER to store Rotate the KNOB clockwise until Normal Op
46. eat Installation 8 Servicing GENERAL Keston Heat CONTENTS 45 amp 55 1 Boiler Assembly Exploded view 9 Natural Gas Boiler u S Sua 7 Destination Countries GB IE RO Commissioning and Testing Electrical Connections Electrical Supply Boiler size G C Appliance No EaultiEinding 49 Benchmark 5 Gas Safety Regulations 41 930 40 86 CN 69 Gas SUD DIY ae ee PUE 5 41 930 41 Introduction 39 Installer Connections 222222222222 24 Installation Mounting Boiler i n n 12 __________________ 4 Performance Data Servicirig n n 41 48 Short Bistiof Parts ERI 59 uu UU S 12 Water GinculatiOns u UU s 5 Water Connections Water System Requirements 8 Water Treatment m 6 IE T ETE 25 Key to symbols Ireland GB United Kingdom Countries of destination 5 Maximum operating pressure of water C53 A room sealed boiler which is connected via its separate ducts to two terminals that may terminate in zones of different pressure C13 A room sealed boiler which is connected its ducts to a horizontally installed terminals that te
47. ectly Is the wiring from the boiler terminal strip to the main PCB securely connected and has continuity Replace main PCB Set the boiler to accept a 0 10V input see Frame 38 Set the boiler to Winter Mode see Frame 38 Ensure between 2V and 10V is correctly connected to these terminals from the external device Ensure that the wiring is securely connected and has continuity Interlock Relay ontacts DHW Tank Sensor eee O 2 0 10V SCRN PE SCRN PE OUO Ong Keston Heat Installation amp Servicing 5 When replacing part on this appliance use only spare parts that you be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Keston Failure to do so could affect safety or performance of this appliance Our Parts team are also available to help with your Keston Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model Appliance GC Number Boiler Serial Number Keston Heat Installation amp Servicing 59 Keston Heating PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 44 0 1482 443005 Fax 44 0 1482 467133 www keston co uk October 2013 UIN 208964 A03 Ke
48. ed water treatment products which must be used in accordance with the manufacturers instructions For further information contact Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ Tel 44 0 870 601 500 or Sentinel Performance Solutions The Heath Business and Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 www sentinel solutions net Notes 1 Itis most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instructions 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS7593 1992 details the steps necessary to clean a domestic heating system 3 In hard water areas treatment to prevent limescale may be necessary however the use of artificially softened water is NOT permitted 4 Under no circumstances should the boiler be fired before the system has been thoroughly flushed ELECTRICAL SUPPLY Wiring external to the appliance MUST be in accordance with the current I E T BS7671 Wiring Regulations and any local regulations which apply For Ireland reference should be made to the current ETCI rules for electrical installations The point of connection to the mains should be readily accessible and adjacent to the boiler CONDENSATE DRAIN Refer to Frames 24 25 amp 60 A condensate drain is provided on the boiler This drain must be c
49. eration is highlighted again and press SELECT to return to normal operation Note that the minimum setpoint after adjustment is 60s Keston Heat Installation 8 Servicing 41 KESTON HEAT USER INTERFACE ADVANCED OPERATING INSTRUCTIONS CONTINUED CHANGING THE NOMINAL ROOM TEMPERATURE ACHIEVED DURING OUTSIDE SENSOR OPERATION O S ROOM TEMP Note that the O S Room Temp Function is only operational if an Outside Sensor has been connected The O S Room Temp is the notional room temperature that the boiler will try to achieve under Weather Compensation operation The default O S Room Temp is 20 C Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Soft Start Time O S Room Temp DHW Sensor Factory Settings Press SELECT and the following screen will be displayed O S Room Temp 20 Press to change to required setting press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation ENABLING THE DOMESTIC HOT WATER THERMISTOR The default is fora DHW Heat Demand to be indicated by a DHW Thermostat providing a 230V input to the DHW Switched Live Instead a DHW Thermistor available as a kit from Keston
50. essible positions which permit the draining of the whole system including the boiler and hot water storage vessel They should be at least 1 2 BSP nominal size and be in accordance with BS 2879 The central heating system should be in accordance with the relevant standards listed on page 4 The Keston boilers feature an integral circulating pump which has sufficient excess head to drive most domestic systems The available head is indicated in the chart below If the system resistance at the desired flow rate is in excess of the available head from the integral pump an additional system pump will be required Keston Heat 55 Hydraulic System Capacity Available System Capacity i 20 deg C differential 15 deg C differential amp g 2 amp 30 35 140 45 50 55 60 65 70 Water Flow Rate L m Keston Heat 45 Hydraulic System Capacity 8 T Available System Capacity 7 1 20 deg differential 15 deg C differential 6 11 deg C differential E 4 2 amp 3 2 0 25 30 GENERAL The schematic below illustrates a recommended approach to using an additional system pump The additional system pump should be sized to overcome the index circuit resistance only as the boilers integral pump will overcome boiler resistance If an additional pump is required the selected pump must
51. imum CH Fan Speed Temperature Control Temperature Heat request OFF Boiler frost protection set point Voltage V continued Keston Heat Installation 8 Servicing INSTALLATION 39 KESTON HEAT USER INTERFACE ADVANCED OPERATING INSTRUCTIONS CONTINUED ENABLING NIGHT SETBACK Note Night Setback is only operational if Outside Sensor has been connecte When Night Setback is enabled the boiler will run at the normal flow temp during CH Demand and reduced temperature when for no demand Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Set to 0 10V Input Set Night Setback DHW Pump Valve Set Booster Press SELECT and the following screen will be displayed Set Night Setback On Off Press and to change to required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation ENABLING VALVE POWER OPEN VALVE POWER CLOSED SHUNT PUMP The boiler default setting is that the boiler pump is always on if a heat demand is present and that a diverter valve can be controlled from the diverter valve system pump connections This can be changed so that the diverter valve
52. ipe Flue Sleeve Flue Sleeve Flange Flexible Wall Wall Plate Seal COOUJTILI E T Keston Heat Installation 8 Servicing 17 FLUE OUTLET 16 FLUE INSTALLATION EXAMPLE KESTON HEAT 55 3 5 back to boiler Air Elbows 2 x 1m 2m Straights 6 2 8m Total 10m INSTALLATION 3 5 back to boiler Bracket at each 1 metre INNNNNNNNNNNNNNNNNNNN Calculations Flue Elbows 3 x 1m 3m Straights 4 6 1 5 1 12 5m Total 15 5m Overall Flue Air 25 5m Air Pipe Length m 17 FLUE INSTALLATION EXAMPLE KESTON HEAT 45 18 7777777777777777777777777777777777777777 7 3 59 to boiler 1 metre 3 5 back to boiler Calculations Flue 3 x 90 elbows Straight lengths Air 4 x 90 elbows 4 Straight lengths 2 2 155 Overall Flue Air 30m Air Pipe Length m Fig 3 Keston Heat 55 Flue amp Air Pipe Length 4 6 8 10 12 Flue Pipe Length m Fig 4 Keston Heat 45 Flue amp Air Pipe Length Acceptable Operating Area 4 6 8 10 12 Flue Pipe Length m Keston Heat Installation amp Servicing INSTALLATION 23 MULTIPLE BOILERS BOILER FRAME AND HEADER KITS Heat output to a maximum of 330kW can be achieved by cascading up to six Keston Heat boilers This can be achieved by the use of Keston Heat boilers fitted side by side on the wall or frames in conjunction with the required header kits
53. le earthed metal 7 Check the operation of the boiler Refer to Frame 53 4 72 USER INTERFACE BOARD 1 Refer to Frame 53 2 Remove the upper front panel amp put the control 75 275212 panel into the service position Refer to Frame AJ 57 3 Fit the earth strap provided with the spare to your wrist and to a suitable earthed metal 4 Pull off all of the main PCB edge connectors refer to Frame 71 5 3 errem Tes Wo 5 Remove the four plastic nuts retaining the main x 2 EN PCB see item 5 in Frame 71 ef 6 Remove the main PCB 7 Pull off the user interface edge connector 8 Unclip the board and lift to clear the six Se mounting posts 9 Fit the new user interface 10 Reassemble in reverse order 10 Check the operation of the boiler Refer to Frame 53 48 Keston Heat Installation amp Servicing 73 FAULT FINDING CHART MAIN MENU Lockout Fill System to 1 Bar Vent System Check Pump Spins Free Reset Boiler Ignition Lockout Check Gas to Boiler Check Condensate Pipe Refer to Instructions Reset Boiler Too Many Resets Turn Boiler Power Off Turn Boiler Power On False Flame Lockout Check Flame Sense Electrode Check Flame Sense Electrode Wiring Low Water Pressure Fill System to 1 Bar Vent System Flame Loss Check Gas to Boiler Check Condensate Pipe Check Flue System Check Flame Sensor Lead Fan Fault
54. lectrical supply such as a double pole savings Once the sensor is fitted it is automatically detected parameters if necessary 31 EXTERNAL WIRING External wiring MUST be in accordance with the current I E T BS7671 Wiring Regulations For Ireland reference should be made to the current ETCI rules for electrical installations The wiring diagrams illustrated in Frames 45 48 cover the systems most likely to be used with this appliance For wiring external controls to the boiler reference should be made to the systems wiring diagram supplied by the relevant manufacturer in conjunction with the connection diagram shown in Frames 32 and 43 48 Difficulty in wiring should not arise providing the following directions are observed 1 The appliance must be wired with a permanent live supply External controls should NOT be wired in series with this mains input Controlling the mains input in this way will prevent the pump over run sequence and may cause damage to the heat exchanger 2 230V AC output is provided optionally for a diverter valve programmer and thermostats Care must be taken to ensure that the earth conductor is longer than the current carrying conductors for reasons given in Frame 29 Keston Heat Installation 8 Servicing This kit provides the facility to apply outside air temperature control to the boiler water flow temperature which provides energy savings The outside sensor provided measures outsid
55. lushing process 52 HANDING OVER ROUTINE OPERATION Full instructions covering routine lighting and operation of the boiler are given on the Lighting and Operation Instruction Label located on the inside of the lower controls door Draw the attention of the boiler owner or his representative to the Lighting and Operating Instruction Label Give a practical demonstration of the lighting and shutting down of the boiler Describe the function of the boiler and system controls and show how they are adjusted and used Hand these Installation and Servicing Instructions User s Instructions and Log book to the customer and request him to keep them in a safe place for ready reference For IE it is necessary to complete a Declaration of Conformity to indicate compliance to the appropriate standard 53 SAFETY It is the law that any service work must be carried out by a Gas Safe Registered Engineer In IE service work must be carried out by a competent person WARNING Always turn off the gas supply at the gas service cock and switch off and disconnect the electricity supply to the appliance and any external controls before servicing or replacing components NOTE When the burner switch is in the off position the boiler control module remains live IMPORTANT After completing the servicing or replacement of components always Test for gas soundness 40 c Refill and vent the system clear all air locks and again
56. n 8 Servicing 7 GENERAL 2 OPEN VENTED SYSTEM REQUIREMENTS Feed expansion cistern Detail reference should be made to the appropriate standards listed on minimum page 4 A The information and guidance given below is not intended to override any requirements of the above publications or the requirements of the local authority gas or water undertakings Open vent 5 The vertical distance between any additional pump and feed expansion cistern MUST comply with the pump manufacturer s minimum requirements to avoid cavitation Should these conditions not apply System either lower the pump position or raise the cistern above the minimum E Y flow to requirement specified by Keston The isolation valves should be fitted P pump as close to the pump as possible Y minimum Inverted cold feed entry The boiler is fitted with an automatic air vent located in the left top side of the interior This air vent must never be shut off as this could result in dry firing of the boiler and subsequent damage to the heat Connections exchanger to boiler ima5351 3 SEALED SYSTEM REQUIREMENTS Note The method of filling refilling topping up or flushing b A manual testing device sealed primary hot water circuit from the mains for a non c Provision for connection of a discharge pipe The domestic property is shown below valve or discharge pipe should be positioned so that the disch
57. n for the water connections in the event of servicing the water circulation pump fitted within the boiler casing IMPORTANT Correct fitment of the safety pressure relief valve must be made to protect the boiler in the event of inadvertent operation when isolated 27 FROST PROTECTION The Keston Heat boiler has built into its control system the facility to protect the boiler only against freezing If the boiler flow temperature T falls below 5 C the pump and burner run until the temperature exceeds 19 C 28 GAS CONNECTION Refer to Frame 1 for details of the position of the gas connection il z 9 e Tee supplied supplied C Isolation Safety Drain Isolation Valve Valve Point Valve supplied supplied supplied supplied Central heating systems fitted wholly inside the building do not normally require frost protections as the building acts as a storage heater and can normally be left at least 24 hours without frost damage However if parts of the pipework run outside the building or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system see Frame 47 In order to determine the actual working gas pressure at the boiler inlet the figure from the table below must be added to the measured pressure refer t
58. n to the Flow Flue Thermistor and check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 KQ At 60 C expect 2 400 2 600 KQ At 85 C expect 1 000 1 100 KQ Is the thermistor value correct Is there continuity between the PCB and the Thermistor 81 RETURN THERMISTOR FAULT 32 Remove the Return Thermistor from the return pipe and disconnect the wires Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 At 60 C expect 2 400 2 600 Q At 85 C expect 1 000 1 1000 Is the thermistor value correct Is there continuity between the PCB and the Thermistor Replace main PCB Rectify wiring amp connections Replace main PCB Replace Fan Fit a new thermistor Check and replace wiring as necessary Replace main PCB Fit a new thermistor Check and replace wiring as necessary Keston Heat Installation amp Servicing FAULT FINDING 82 OUTSIDE SENSOR FAULT Is the wiring securely connected at both the boiler and Securely connect the wiring at both Outside Sensor the boiler and Outside sensor Disconnect the wires to the Outside Sensor Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 0 C expect 32 000 33 000 At 10 C expect 19 000 21 000 At 20 C expect 12 000 13 000
59. ner Refer to Frames 56 and 57 5 Inspect the heat exchanger through the burner opening If there are signs of aluminium oxide build up spray water down the flueways Refer to Frame 58 6 Remove the sump cover and scrape out any deposits Refer to Frame 59 7 Remove the condensate trap and flush through with water Refer to Frame 60 8 Check that the flue terminal is unobstructed and that the flue system is sealed correctly 9 After completion of servicing refer to Frame 53 for reference to final safety checks 55 CASING REMOVAL Front Panels 1 Pull the two sides of the control casing door to open 2 Remove the two screws retaining the front panel lift the panel to remove 3 Remove the two screws retaining the control panel and swing the panel down into the service position Side Panels Note Removal is not required for normal service 1 Remove the two or three screws from the top and bottom of the side panels 2 Re assemble in reverse order Keston Heat Installation amp Servicing SETTING TO MAXIMUM OUTPUT Ensure that there is a current CH demand to the boiler e g the CH Switched Live is on Press SELECT and the following screen witll be displayed The kW output number in the 1st line will vary depending on the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 1st stat clockwise until the following screen is displayed Keston 45k
60. ng boiler location Plastic with push fit or solvent connections c Internal plastic pipe work a minimum of 19mm ID typically 22mm OD d External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation g Allinstallations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams amp BS6798 2009 h Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage through freezing i All internal burrs should be removed from the pipe work and fittings In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted Internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc See Figs 1 and 2 Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate trap Min 2 19mm P ad Internal pipe 2
61. ns from the switch Unscrew the water pressure switch Refit new switch Connect electrical connections Refill the system ensuring all the air escapes via the air vent o p N 0 0 P OQ Reassemble in reverse order 10 Check the operation of the boiler Refer to frame 53 68 FLOW RETURN THERMISTOR REPLACEMENT Refer to Frame 53 FLOW Remove the front panel Refer to Frame 55 Isolate the water circuit and drain the system B5 UNa Disconnect the electrical connections from the thermistor Unscrew the thermistor 6 Fit the new thermistor with built in O ring seal Do not overtighten RETURN 7 Refill the system ensuring all the air in the heat exchanger is vented through the air vent 8 Re assemble in reverse order 9 Check the operation of the boiler Refer to Frame 53 46 Keston Heat Installation amp Servicing SERVICING 69 FLUE THERMISTOR REPLACEMENT 1 Refer to Frame 53 2 Remove the front panel Refer to Frame 55 3 Disconnect the electrical connections from the thermistor 4 Unscrew the thermistor 5 Fit the new thermistor with gasket seal DO NOT overtighten 6 Re assemble in reverse order 7 Check the operation of the boiler Refer to Frame 53 70 PUMP HEAD REPLACEMENT 1 Refer to Frame 53 9 Withdraw the power supply cable through the grommet 2 Remove the front panel Refer to Frame 55 10 Remove the four 5 allen bolt
62. nt Hot Water Temp 0 10V Capacity Operating Mode If 0 10V Capacity operation is ongoing screens similar to the 0 10V Operation following will be displayed 0 10V Input Line 3 indicates the current operating State Pre Purge or Ignition Burner On or Burner On or Pump Overrun Sumner Sepai teigi Flow Temp and Burner Power will vary as the boiler operates Flow Temp 0 10V Input and Burner Setpoint Target will vary as the external Building Management System controls them See Frame 38 for configuring the boiler for 0 10V Capacity Operation 0 10V Temperature Operating Mode If 0 10V Temperature operation is ongoing screens similar to the following will be displayed Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Flow Temp and Burner Power will vary as the boiler operates 0 10V Input and Flow Setpoint will vary as the external Building Management System controls them See Frame 38 for configuring the boiler for 0 10V Temperature Operation 0 10V Operation 0 10V Input Burner On Flow Setpoint Flow Temp Keston Heat Installation amp Servicing Central Heating Burner Power Outside Temp Flow Setpoint Flow Temp Boiler Frost Protect Burner Power Outside Temp Frost Setpoint Flow Temp System Frost Protect Flow Temp Burner On Frost Setpoint Outside Temp Cylinder Frost Protect Burner Power Outside Temp Frost Setpoint Hot Water Temp
63. nting Plate Terminals 2 off Flue Sleeve Wall Plate amp Screws Wall Seal Weather Compensation Screws 4 off Wall Plugs 4 off OTUZ lt gm gt 10 Keston Heat Installation 8 Servicing INSTALLATION 7 WALL MOUNTING TEMPLATE Note Horizontal flue runs must be inclined at 3 5 to the horizontal to allow condensate Note The template shows the positions for the to drain back tothe boiler top fixing holes Care must be taken to ensure the correct holes are drilled 1 template into the selected position 2 Ensure squareness by hanging a plumbline 3 Mark on to the wall a The top 4 wall mounting plate screw At 7 positions BOILER TOP SOUS WIN 1007190 FLUE DRILL 4 HOLES 012 0 WITH PREFERENCE FOR OUTSIDE HOLES FOR_POSITION OF BOTTOM FIXING HOLES REFER TO INSTALLATION INSTRUCTIONS b The 2 boiler lower fixing positions using diagram below WALL MOUNTING TEMPLATE c The position of the flue duct Mark the centre of the hole as well as the circumference BOILER SIDE BOILER SIDE CLEARANCE 25mm MIN CLEARANCE 25mm MIN TRIM ALONG DOTTED LINE IF REQUIRED 4 INIT SNOW MINL 4 Remove the template from the wall 120 245 365 490 Does not apply to air intake BOILER LOWER FIXING POSITIONS
64. o Frame 56 A MINIMUM working gas pressure of 17 5 mbar 7 w g must be available at the boiler inlet for natural gas with the boiler firing Refer to Frame 58 for details of the pressure test point position Keston Heat Gas Line Pressure Drop Natural Gas Extend a gas supply pipe NOT LESS THAN 22mm O D to the boiler and connect using the gas cock provided IMPORTANT The gas service cock contains a non metallic seal so must not be overheated when making capillary connections 22 Note It should be noted that this pressure drop is present within the internal boiler pipe work and is irrespective of the fact that manifold headers are used This pressure drop will be experienced on each individual boiler regardless of single or multiple installation Keston Heat Installation amp Servicing INSTALLATION 29 ELECTRICAL CONNECTIONS Warning This appliance MUST be efficiently earthed A mains supply of 230V 50Hz is required The supply wiring MUST be suitable for mains voltage Wiring should be 3 core PVC insulated cable NOT LESS than 0 75mm 24 x 0 2 mm and to BS 6500 Table 16 The fuse rating should be 5A Wiring external to the boiler MUST be in accordance with the current BS7671 Wiring Regulations and any local regulations For Ireland reference should be made to the current ETCI rules for electrical installations Connection should be made in a way that allows complete isolation of the e
65. of 16 0m 50mm muPVC are used In such cases the boiler output will be reduced by 0 896 per additional metre The maximum lengths of both air inlet pipe and flue outlet pipe when no bends are used are as detailed in figs 3 amp 4 However each bend used has an equivalent length that must be deducted from the maximum straight length stated in figs 3 amp 4 Knuckle bends must not be fitted A 92 5 swept elbow is equivalent to 1 0m straight length A 45 bend is equivalent to 0 5m straight length It is possible to have variable flue and air lengths as described within the shaded area of Figs 3 amp 4 Fig 3 Fig 4 Keston Heat 55 Flue amp Air Pipe Length Keston Heat 45 Flue amp Air Pipe Length Air Pipe Length m Air Pipe Length m 2 4 6 8 Flue Pipe Length m Flue Pipe Length m SLOPE Horizontal flue outlet pipework MUST slope at least 3 5 degrees 60 per metre run downwards towards the boiler Pipework can be vertical Only swept elbows can be used Air inlet pipework can be truly horizontal or vertical or sloping in a downward direction towards the boiler but in each case rain etc must be prevented from entering the pipe There must be no troughs in any of the pipework whether it be air inlet or flue outlet FLUE OUTLET 14 Keston Heat Installation amp Servicing INSTALLATION 13 FLUE TERMINATION POSITION Twin Flue Positions Flue Minim
66. onnected to a drainage point on site All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Installation must be in accordance with BS 6798 The drain outlet on the boiler is sized for standard 21 5mm 3 4 overflow pipe It is a universal fitting to allow use of different brands of pipework Note that all external runs must be insulated Keston Heat Installation 8 Servicing GENERAL 1 BOILER CLEARANCES AND CONNECTIONS The following minimum clearances must be maintained for operation and servicing Front of boiler 450mm Sides of boiler 25mm Above boiler 350mm Below boiler 300mm Clearance between multiple boiler installations 25mm Minimum Top Clearance Flue Centre Line j Flue Centre Line j Flue Centre Line 2 o c o Flow Return 206210 10155 Sa VLL Front clearance The minimum front clearance when built in to cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Keston Heat Installatio
67. or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a Gas Safe Registered Engineer or in IE by a competent person It must be carried out in accordance with the relevant requirements of the Gas Safety Installation and Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland The Water Fittings Regulations or Water byelaws in Scotland Current I E T Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Competent Person and installed in accordance with the current edition of 1 5 813 Domestic Gas Installations or 1 5 820 Non Domestic Gas Installations as appropriate the current Building Regulations and reference should be made to the current ETCI rules for electrical installation The Keston Heat boilers have been tested and certified to EN 483 EN 677 BSEN 60335 2 102 BSEN 55014 1 and BSEN 55014 2 for use with Natural Gas Detailed recommendations are contained in the following Codes of Practice BS 6891 Installation of low pressure gas pipework of up to 28mm R1 in domestic premises 2nd family gas Inst and maintenance of
68. pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered Grip the boiler at the base Be physically capable Use personal protective equipment as appropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip with the palm of the hand Use designated hand holds Keep load as close to the body as possible Always use assistance if required Keston Heat Installation 8 Servicing GENERAL SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler must not be fitted outside GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier A gas meter can only be connected by the local gas supplier or by a Gas Safe
69. r Central Heating select Winter Mode For Hot Water select Summer or Winter If the boiler has been switched to Standby Mode the following screen will be displayed No Boiler operation will take place with this setting See Frame 36 to change to Summer or Winter setting Summer Mode If the boiler has been switched to Summer Mode a screen similar to the following will be displayed line 5 may vary depending on setup Domestic Hot Water operation will take place with this setting but Central Heating will not No Hot Water Demand See Frame 36 to enable Central Heating by changing to Winter setting Switched Live 2 Summer Mode For Central Heating Winter Mode If there is no current Heat Demand a screen similar to the following will be displayed line 5 may vary Vues depending on setup Demand Line 5 indicates Switched Live or or 0 10 depending on which controls No Hot Water Demand connected to the boiler Switched Live 1 Domestic Hot Water Mode DHW Thermostat If there is an ongoing Domestic Hot Water Demand using a DHW Thermostat screens similar to the following will be displayed Line 2 indicates whether Switched Live or OpenTherm is controlling the boiler Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Burner Power and Flow Temperature will vary as the boiler DHW 230V Operation DHW 230V Operation Switched Live 2 On Burner Power
70. rame 80 amp 81 the boiler in excess of 30 C yes Replace the pump then reset the boiler Check that the pump is rotating freely Is the differential now below 20 C yes Reset the boiler 75 IGNITION LOCKOUT 5 22 Check the detection electrode and associated harness for continuity visual condition and position refer to short time and then extinguish Frame 65 Check if the condensate pipe is blocked no no Is the gas pressure available at the boiler gt 18mbar Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB Unplug the Gas Valve is the resistance between the n gt Replace Gas Valve outside pins between 1kQ and 10kQ Check Spark Generator and associated Harness for Replace Spark Generator and continuity visual condition and position refer to Frame Harness as necessary 64 Are these functioning correctly Check Ignition Electrode and associated Harness for cae Pecrode and continuity visual condition and position refer to Frame 64 Are these functioning correctly Is the following voltage available at the Gas Valve approximately 215Vdc Check Syphon and condensate drain pipework for blockage Replace Gas Valve and rectify if necessary Boiler now working OK 9 2 a a 5 9 2 a L 5 9 2 a 2 F 5 9 2 a L lt 9 a E 5 4 9 2 a L 5 5
71. rely connected Is an External Interlock connected to the boiler across the terminals marked External Interlock in the boiler terminal strip yes Has the External Interlock operated Reset the External Interlock Ensure the wiring has continuity and is Does the wiring from the Interlock Relay mounted securely connected within the boiler to the terminal strip have continuity and is securely connected yes Replace the Interlock Relay Kit 86 BCC FAULT Securely attach the correct BCC for the boiler onto the PCB Note ensure the correct orientation of the BCC by placing the side marked upwards Is the correct BCC for the boiler securely inserted into the slot at the front left of the PCB identified by the label on the BCC Replace the BCC with a new BCC that is correct for the boiler After switching power on and resetting the boiler does the fault disappear Replace main PCB 9 2 a 5 5 9 2 a 5 5 9 2 a 5 5 2 a 5 5 L 9 a L F 5 9 2 a 2 E 5 54 Keston Heat Installation 8 Servicing FAULT FINDING 87 NOCH BUT DHW OK Is the boiler set for Winter operation Set for Winter operation see Frame 36 yes Are the Timer and Room Thermostat calling for Heat Ensure that the Timer and Room Thermostat are calling for heat yes Are the Radiator Valves open Open the Radiator Valves yes Is an OpenTherm de
72. rminate within a common pressure zone I2H An appliance designed for use on 2nd Family gases NOTE TO THE INSTALLER LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER Keston Heat Installation amp Servicing 3 GENERAL INTRODUCTION The Keston Heat boilers are fully automatically controlled wall mounted fanned super efficient condensing appliances The Keston Heat condensing boilers can be installed either on the wall or into a prefabricated floor mounted frame Through a sophisticated control system combined with premix burner arrangement the boilers are capable of high seasonal efficiencies of gt 96 and low emissions These boilers are certified to meet the requirements of the EC Gas Appliance Directive Boiler Efficiency Directive EMC and Low Voltage Directive Note These boilers cannot be used on systems that include gravity circulation The boiler are suitable for connection to fully pumped open vented or sealed water systems Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework Boiler is suppled with internal pump OPTIONAL EXTRA KITS Air Terminal Finishing Kit Programmable Room Thermostat Kit Modulating Sequencer Kit Tank Sensor Kit Safety Interlock Kit Flue Sleeve Kit Room Sensor Kit Frame and Header Kit SAFETY Current Gas Safety Installation and Use Regulations
73. s securing the pump head to 3 Isolate water at the flow amp return shut off valves beneath body A high torque is required to release these bolts a boiler long 4mm T bar allen key is required 4 Drain the water from the boiler via the drain cock adjacent 11 Withdraw the pump head from the body to the shut off valve 12 Remove the PWM cable plug from the pump head 5 Drop down the control panel door 13 Remove the pump head through the bulkhead aperture 6 Remove the four M4 screws securing the access aperture cover plate Care should be taken to avoid water spillage onto the PCB 7 Remove the cover plate by pulling forward the flange at the top connections when withdrawing the pump head through the 8 Disconnect the pump power supply at the left hand aperture There is a plug situated in the boiler casing floor terminal strip directly beneath the pump to allow drainage of any spillage within the casing 10 Keston Heat Installation 8 Servicing 47 SERVICING SERVICING SERVICING 71 MAIN PCB REPLACEMENT 1 Refer to Frame 53 4 Pull off all of the main PCB connectors 2 Remove the upper front panel amp put the control panel into the service position Refer to Frame 55 a Remove the four plastic nuts retaining the main PCB 6 Fit new PCB and BCC BCC must be fitted or boiler 3 Fit the earth strap provided with the spare PCB to will not work and re assemble in reverse order your wrist and to a suitab
74. sensor DHW demand can be controlled by 230V programmer and or cylinder thermostat tank sensor kit The electrical supply and their inputs onto the boiler can be seen in Frames 32 and 43 48 4 An optional outside temperature sensor may be fitted for outside weather compensation See Frame 32 for connection details 23 INSTALLATION INSTALLATION OO 01 0 0809 yuel AS Jeuondo 108095 AS wey AS euondo V O OIE 32 INSTALLER CONNECTIONS esn 101100 suonoeuuoo sng 941 Buum jeujejur Bunsix y u pesn Ajuo pesn eq jou suonoeuuoo 1914094 eu p IM eui uonounfuoo pesn juo eie suonoeuuoo sjoejuo xoo jeju pue 991 20 1 1 1 ioq BU eq pinous sj JOSUaS xue MHA pue 2 AjUO UO SI u uA sj2ejuoo uo eu sinooo e Jaye IM s opluoo Aejay 8913 HOA 1109201 941 104 129 1108411 OO 9EAO0 C jeuondo a HO JO 28062 jeuondo O O O
75. stat clockwise until a screen similar to following is displayed Keston 45kW Fault History Show Hours Run Normal Operation Press SELECT and a screen similar to the following will be displayed Show Hours Run Total Hours 20h Flame 10h The times will vary depending on the operation of the boiler Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation continued 29 INSTALLATION INSTALLATION 30 INSTALLATION 38 KESTON HEAT USER INTERFACE ADVANCED OPERATING INSTRUCTIONS SETTING TO 0 10V Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Show Hours Run Set to 0 10V Input Set Night Setback DHW Pump Valve Press SELECT and the following screen will be displayed Set to 0 10V Input 0 10V Off 0 10V Capacity 0 10V Temperature Press and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation 0 10V Capacity Control is governed by the following relationship Capacity Control Maximum CH Fan Speed Fanspeed rpm Heat request is OFF Min
76. ston pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice
77. t the Gas Valve approximately 215Vdc See note Check Spark Generator and associated Harness for continuity visual condition and position refer to Frame 64 Are these functioning correctly Replace Spark Generator and Harness as necessary Check Ignition Electrode and associated Harness for continuity visual condition and position refer to Frame 64 Are these functioning correctly Check Syphon and condensate drain pipework for blockage and rectify if necessary Boiler now working OK Replace Gas Valve Note due to the wave form of the rectified voltage the reading will vary depending on the type of meter used to measure the value In general terms a reading of greater than 150V indicates that the correct voltage is supplied to the gas valve Replace Ignition Electrode and associated Harness as necessary FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING Keston Heat Installation amp Servicing 51 9 2 a 5 5 u 9 2 a 5 5 9 2 a F 5 L 9 2 a L 5 5 9 a E m 5 L 9 2 a 5 5 FAULT FINDING 79 FAN FAULT Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated Does the wiring have continuity Is there 230Vac at the blue and brown connections to the 3 way connection on the Fan 80 FLOW amp FLUE THERMISTOR FAULT Disconnect the electrical connectio
78. tance to earth and short circuit using a suitable meter In IE refer to 1 5 813 2002 WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE 38 Keston Heat Installation 8 Servicing INSTALLATION 50 INITIAL LIGHTING 1 Check that the system has been filled and the boiler is not air locked 6 air in the boiler could damage the heat exchanger For this reason the airvent located in the left top side must never be shut off 2 Check that all the drain cocks are closed and any valves in the flow and return are open 7 3 Check that GAS SERVICE COCK IS 4 Fill the condensate trap with water before putting the unit into operation see Frame 60 for condensate trap removal 8 5 Check the indication on the pressure gauge If the pressure is less than 1 bar the installation should be filled up first sealed system only Keston Heat Flue CO measurements hot condition Switch the electricity supply ON and check that all the external controls are calling for heat Check boiler is set for winter operation see Keston Heat user interface basic operating instructions The boiler will commence the ignition sequence If after 5 attempts the boiler has failed to light then it will lock out Press the reset button to restart the ignition sequence Operate the boiler for 10 minutes and check the gas rate
79. tat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode Anti Legion Temp Anti Legion Enable BUS Address Flame Relay Press SELECT and the following screen will be displayed Anti Legion Enable On Off Press and to change to required setting then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation continued Keston Heat Installation 8 Servicing INSTALLATION 43 KESTON HEAT WITH S PLAN SYSTEM Note that a hydraulic bypass is required to allow pump overrun Note that a Frost Stat can be connected into CH call 8 Plan X Val alve 1 Use the outside sensor then the link from position 9 to position 10 in the installer terminal block should be removed and a wire added from position 10 to the DHW Call input on the boiler S Plan Valve Fused Spur 25250 o n 5 Pump7DV ron amp 9 920 SF Keston Heat Installation 8 Servicing
80. tes The boiler will automatically configure itself to a Switched Live input The Switched Live must be from the same phase as the boiler mains supply AFrost Thermostat can be connected into the CH Call Input DHW Pump DV Rectifier Mains In Switched Live External Controls EXTERNAL CONTROLS VIA 0 10V INPUT The boiler must be set fpr 0 10V input See Frame 38 UAL AL DHW 0 11 n 0050 2 HORORORORNO 11 n ORO O U ri n U n CH Pump OnOrOnOrO LI OUO LI O LU Uu OnOnO 206210 10236 EXTERNAL CONTROLS VIA OPENTHERM The boiler will automatically configure itself to an Opentherm input Rectifier DHW Pump DV 0200020000 s pasi OnOnOnOno OROHORORORO n CH Pump no LI External Controls
81. thod see manufacturers detailed instructions Visible air break Boiler with 75mm 2 sealed condensate trap Min 19mm Internal pipe Condensate pump Install in accordance with manufacturers instructions Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate tra P Water weather proof insulation Min 19mm Internal pipe combined foul rain water drain Min 30mm Internal pipe External air break Air gap 1 Terminated and cut at 459 pup 43mm 90 male 68mm PVCU female bend 27 Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm sealed condensate trap Min 30mm Internal pipe Water Weather proof insulation Min 19mm Internal nip Max 3m external Limestone chippings Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Keston Heat Installation amp Servicing Figure 4 Connection of condensate Drainage Pipe to External Soil amp Vent Stack Boiler with 75mm sealed condensate Min 2 19mm Internal 57
82. ued Keston Heat Installation amp Servicing INSTALLATION 37 KESTON HEAT USER INTERFACE BASIC OPERATING INSTRUCTIONS CONTINUED VIEWING THE STATE OF THE BOILER INPUTS Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 151 stat clockwise until a screen similar to the following is displayed Keston 45kW Out Sensor Slope State of Inputs State of Outputs Fault History Press SELECT and a screen similar to the following will be displayed State of Inputs Flow Temp Return Temp Flue Temperature Press for more The state of the iniputs will vary as the boiler operates Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation VIEWING THE STATE OF THE BOILER OUTPUTS Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the maximum output of the boiler Keston 45kW Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate 1st stat clockwise until a screen similar to the following is displayed Keston Heat State of Inputs State of Outputs Fault History Show Hours Run Press SELECT and a screen similar to the following will be
83. ues given in Frame 50 Carry out functional checks as appropriate Keston Heat Installation amp Servicing SERVICING 54 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually Keston does not accept any liability resulting from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the Company s recommendations and specifications Note Some aluminium oxide build up within the heat exchanger assembly is quite usual with this type of condensing boiler 1 Light the boiler and carry out function checks noting any operational faults 2 Run the boiler for 5 minutes and then check the gas consumption rate Refer to procedure opposite on how to force the burner to maximum rate 3 Optional test Connect a suitable gas analyser to the sampling point fitted in the flue adapter For correct boiler operation the CO CO ratio of the flue gas should not be greater than 0 004 ratio and the CO values should match those in table 1 If this is the case and the gas input is at least 90 of the nominal once compliance with the note above is ensured then no further action need be taken If not proceed to 4 4 Remove and clean the bur
84. um Spacing Air Minimum Spacing Below an opening 1 300 mm 50 mm Above an opening 1 300 mm 50 mm Horizontally to an opening 1 300 mm 50 mm Below gutters soil pipes or drain pipes 75mm 75 mm Below eves 200 mm 50 mm Below balcony or car port roof 200 mm 50 mm From a vertical drain pipe or soil pipe 150 mm 50 mm From an internal or external corner or to a boundary alongside the terminal 300 mm 50 mm Above ground roof or balcony level 300 mm 100 mm From a surface or a boundary facing the terminal 600 mm 100 mm From a terminal facing the terminal 1200 mm 1200 mm From an opening in the car port into the building 1200 mm 100 mm Vertically from a terminal on the same wall 1500 mm 1500 mm Horizontally from a terminal the same wall 300 mm 300 mm 1 An opening here means an openable element such as a openable window or a fixed opening such as an air vent However in addition the outlet should not be nearer than 150mm fanned draught to an opening into the building fabric formed for the purpose of accommodating a built in element such as a window frame z lr a The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions boundary boundary GENERAL INSTALLATIONS parts of the system must be constructed in accordance with BS 5440 Part 1 except where specifically mentioned in these instructions
85. ve complying with prevention device the relevant requirements of BS 6759 Pt 1 RP2 valve assembly must be fitted in the flow pipe as close to the boiler as possible and with no intervening Strainer valve or restriction The valve should have the following features a Anon adjustable preset lift pressure not exceeding 4 bar 60 Ibf in BOILER Y The supplied Pressure Relief Valve is for boiler protection only in the event that the flow and return isolators have been turned Air off If converting to a sealed system a gap separately sized PRV suitably sized will Tundish need to be fitted in addition on the heating CV Control Valve Supply circuit DT Drain Tap pipe Resillient seat control valves ima7349 8 Keston Heat Installation 8 Servicing 105 Auto Air Vent 208 Burner Fixings Kit 230 Fan 231 Gas Valve Kit 232 Venturi Kit 301 Dry Fire Thermistor Kit 302 Lead Ignition Kit Keston Heat Installation 8 Servicing INSTALLATION 304 305 306 308 309 310 501 Kit 4 BOILER ASSEMBLY Exploded View Ignitor Unit Electrode Detection Kit Ignition Electrode Kit Fascia Plastic HMI Board Primary PCB Jacket Assembly Keston Heat 502 508 509 510 Door Assembly Keston Heat Kit Flue Stat Bulk Head Acccess plate Pump INSTALLATION INSTALLATION INSTALLATION 5 PACK
86. vice connected to the boiler note that yes the Keston Prog Room Stat is an OpenTherm device There is no voltage from the Timer Is there 230Vac at A Room Stat This is not a boiler fault Ensure voltage is supplied to the boiler by correcting external wiring Rectify wiring from boiler to OpenTherm device Is there 230Vac at B Check wiring from PCB to B yes Does wiring to Pump have continuity and is to the is Rectify wiring to pump correct connections yes 15 the pump stuck Replace the pump yes Free the pump FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING LiveOut SL ET Keston Heat Installation 8 Servicing 55 FAULT FINDING 88 NO DHW BUT CH OK s the 2 gt Ensure that Timer and Cylinder Stat Thermistor Or Cat are calling for heat if a DHW Thermistor is used yes see Frame 36 for setting DHW Temp Is an OpenTherm device connected to the boiler note that Keston programmable Does the wiring from the boiler to the Room Stat is an OpenTherm device OpenTherm device have continuity There is no voltage from the Timer Cylinder Stat This Recut wiring no Is there 230Vac at is not a boiler fault Ensure Hom beter voltage is supplied to the boiler f yes by correcting external wiring Replace the diverter valve no Is the Diverter Valve stuck yes Free the diverter valve 9 2 a 5 5 9 2 a
87. wing screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode 2nd SL DHW CH CH DHW Priority Set Max Flow Temp Set Min Flow Temp Press SELECT and the following screen will be displayed CH DHW Priority Priority DHW Priority CH Priority Equal Press and to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation 32 CHANGING THE MAXIMUM FLOW TEMPERATURE SETPOINT Boiler default setting is that maximum flow temperature setpoint is 82 This feature limits the maximum flow temperature that can be set in the Basic Operating Mode Press SELECT and then hold and down together for more than 5s the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Rotate the 1st stat clockwise until the following screen is displayed Installer Mode CH DHW Priority Set Max Flow Temp Set Min Flow Temp Sys Frost Protect Press SELECT and the following screen will be displayed Set Max Flow Temp 80 Press to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to norm

Keston Heat 45kw Installation Manual

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